Hydrocarbon hydrogenation catalyst and process

ABSTRACT

A catalyst composition and process for preparing such catalyst composition which can be useful in contacting a hydrocarbon-containing fluid which contains a highly unsaturated hydrocarbon such as 1,3-butadiene, in the presence of hydrogen, with such catalyst composition in a hydrogenation zone under a hydrogenation condition effective to hydrogenate such highly unsaturated hydrocarbon to a less unsaturated hydrocarbon such as n-butene is disclosed. Such process for preparing a catalyst composition includes (1) combining a zeolite, a Group VIB metal, and an inorganic support to form a modified zeolite; (2) calcining such modified zeolite under a calcining condition to produce a calcined, modified zeolite; and (3) contacting such calcined, modified zeolite with a carburizing agent under a carburizing condition to provide such catalyst composition.

This application is a division of application Ser. No. 09/408,824 filedon Sep. 29, 1999, now U.S. Pat. No. 6,235,954.

BACKGROUND OF THE INVENTION

This invention relates to a catalyst composition, the preparation of acatalyst composition, and to a process of using a catalyst compositionfor hydrogenating a highly unsaturated hydrocarbon.

It is well known to one skilled in the art that an unsaturatedhydrocarbon can be produced by a thermal cracking process. For example,a fluid stream containing a saturated hydrocarbon such as, for example,ethane, propane, butane, pentane, naphtha, or combinations thereof canbe fed into a thermal (or pyrolytic) cracking furnace. Within thefurnace, the saturated hydrocarbon is converted to a less unsaturatedhydrocarbon such as, for example, ethylene and propylene. Lessunsaturated hydrocarbons are an important class of chemicals that find avariety of industrial uses. For example, ethylene and propylene can beused as a monomer or comonomer for producing polyolefins. Other uses ofless unsaturated hydrocarbons are well known to one skilled in the art.

However, a less unsaturated hydrocarbon produced by a thermal crackingprocess generally contains an appreciable amount of highly unsaturatedhydrocarbons such as less desirable alkyne(s), diolefin(s), polyene(s),or combinations thereof. For example, ethylene produced by thermalcracking of ethane is generally contaminated with some acetylene whichmust be selectively hydrogenated to ethylene, but not to ethane, in ahydrogenation reaction. Similarly, in a thermal cracking process forproducing a butene, butynes and butadienes are generally co-producedwhich must be selectively hydrogenated to a butene, but not furtherhydrogenated to a butane.

These highly unsaturated hydrocarbons described above are undesirablefor several reasons. Generally, these highly unsaturated hydrocarbonsare highly reactive and tend to polymerize by forming gums if they areleft in the product stream. Also, these undesirable products can have aneffect on further processes, such as alkylation. Thus, these highlyunsaturated hydrocarbons are preferably removed. A preferred process forremoving such undesirable highly unsaturated hydrocarbons is a selectivehydrogenation process. This process not only minimizes the loss ofdesired less unsaturated hydrocarbons, but can also help to avoid a“runaway” reaction which is difficult to control in front-end andtotal-cracked-gas processes thereby increasing the selectivity by whichdesired products, as opposed to undesired products, are produced.

Catalysts comprising palladium and an inorganic support are knowncatalysts for the hydrogenation of highly unsaturated hydrocarbons suchas alkynes and/or diolefins. Sulfided catalysts comprising a metalselected from the group consisting of molybdenum, cobalt, and nickel andcombinations thereof have also been used as hydrogenation catalysts.However, these catalysts can be expensive to prepare and can have thepotential to introduce sulfur contaminants which can poison anddeactivate catalysts used in hydrogenation processes.

As such, development of a catalyst which is cost-efficient and easier toprepare than known catalysts and processes therewith in the selectivehydrogenation of a highly unsaturated hydrocarbon such as a diolefin toa less unsaturated hydrocarbon such as a monoolefin in which selectivityis improved and unnecessary introduction of contaminants is avoidedwould be a significant contribution to the art and to the economy.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a catalyst compositionwhich can be useful as a catalyst in the selective hydrogenation of ahighly unsaturated hydrocarbon such as a diolefin to a less unsaturatedhydrocarbon such as a monoolefin.

It is another object of this invention to provide a process forproducing such catalyst composition which can be useful as a catalyst inthe selective hydrogenation of a highly unsaturated hydrocarbon such asa diolefin to a less unsaturated hydrocarbon such as a monoolefin.

It is another object of this invention to employ such catalystcomposition in a process for selectively hydrogenating a highlyunsaturated hydrocarbon such as a diolefin to a less unsaturatedhydrocarbon such as a monoolefin.

Advantages of this invention include a catalyst composition which avoidsunnecessary introduction of contaminants which can poison and deactivatecatalysts used in hydrogenation processes. Another advantage of thisinvention is that the process of making such catalyst is cost-efficientand easier to prepare than known catalysts. Yet another advantage ofthis invention is an increased or enhanced selectivity to a desiredproduct such as a less unsaturated hydrocarbon.

The present invention is directed to a catalyst composition whichcomprises a carburized, calcined, modified zeolite having incorporatedtherein a metal of Group VIB of the Periodic Table of the Elements(i.e., a Group VIB metal) such as chromium, molybdenum, tungsten andcombinations thereof. The composition also comprises an inorganicsupport. The inorganic support can be selected from the group consistingof silica, alumina, titanium dioxide, zirconia, a spinel such as zincaluminate, zinc titanate, magnesium aluminate, calcium aluminate, andthe like and combinations thereof.

The present invention is also directed to a process for producing acatalyst composition which can be useful as a catalyst in the selectivehydrogenation of a highly unsaturated hydrocarbon such as a diolefin toa lower unsaturated hydrocarbon such as a monoolefin. The process cancomprise: (1) combining a zeolite, a metal of Group VIB of the PeriodicTable of the Elements (i.e., a Group VIB metal), and an inorganicsupport to form a modified zeolite; (2) calcining such modified zeoliteunder a calcining condition to produce a calcined, modified zeolite; and(3) contacting such calcined, modified zeolite with a carburizing agentunder a carburizing condition to provide a carburized, calcined,modified zeolite.

The present invention is also directed to a process which can be used toemploy a catalyst composition of this invention in the selectivehydrogenation of a highly unsaturated hydrocarbon such as a diolefin toa less unsaturated hydrocarbon such as a monoolefin. The process cancomprise contacting a hydrocarbon-containing fluid, which comprises ahighly unsaturated hydrocarbon, in the presence of hydrogen with acatalyst composition in a hydrogenation zone under a hydrogenationcondition effective to selectively hydrogenate a highly unsaturatedhydrocarbon to a less unsaturated hydrocarbon. The catalyst compositioncan be a catalyst composition of the present invention.

Other objects and advantages of the invention will be apparent from thedetailed description of the invention and the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

As used in the present invention, the term “hydrocarbon” generallyrefers to, unless otherwise indicated, one or more hydrocarbons,saturated or unsaturated, having in the range of from about 1 carbonatom per molecule to about 50 carbon atoms per molecule, preferably inthe range of from about 2 carbon atoms per molecule to about 40 carbonatoms per molecule, more preferably in the range of from about 2 carbonatoms per molecule to about 30 carbon atoms per molecule and, mostpreferably, in the range of from about 2 carbon atoms per molecule toabout 20 carbon atoms per molecule. Preferably, a hydrocarbon is asaturated hydrocarbon, a mixture of saturated hydrocarbons, or a mixtureof saturated hydrocarbons and less unsaturated hydrocarbons. Also, asused in the present invention, the term “fluid” denotes gas, liquid,vapor, or combinations thereof.

The term “saturated hydrocarbon” refers to any hydrocarbon which doesnot contain any carbon-to-carbon double bonds or carbon-to-carbon triplebonds. Examples of saturated hydrocarbons include, but are not limitedto, ethane, propane, butanes, hexanes, octanes, decanes, naphtha, andthe like and combinations thereof.

The term “highly unsaturated hydrocarbon” refers to a hydrocarbon havinga carbon-to-carbon triple bond or two or more carbon-to-carbon doublebonds. Examples of highly unsaturated hydrocarbons include, but are notlimited to, aromatic compounds such as benzene and naphthalene; alkynessuch as acetylene, propyne (also referred to as methylacetylene), andbutynes; diolefins such as propadiene, butadienes, pentadienes(including isoprene), hexadienes, octadienes, and decadienes; and thelike and combinations thereof.

The term “less unsaturated hydrocarbon” refers to a hydrocarbon in whicha carbon-to-carbon triple bond in a highly unsaturated hydrocarbon ishydrogenated to a carbon-to-carbon double bond, or a hydrocarbon inwhich the number of carbon-to-carbon double bonds is one less, or atleast one less, than that in a highly unsaturated hydrocarbon, or ahydrocarbon having at least one carbon-to-carbon double bond. Examplesof less unsaturated hydrocarbons include, but are not limited to,monoolefins such as ethylene, propylene, butenes, pentenes, hexenes,octenes, decenes, and the like and combinations thereof.

The term “hydrogenation process” refers to a process which hydrogenatesa highly unsaturated hydrocarbon such as an alkyne or a diolefin to aless unsaturated hydrocarbon such as a monoolefin or a saturatedhydrocarbon such as an alkane. The term “selective” refers to suchhydrogenation process in which a highly unsaturated hydrocarbon such asan alkyne or a diolefin is hydrogenated to a less unsaturatedhydrocarbon such as a monoolefin without further hydrogenating such lessunsaturated hydrocarbon to a saturated hydrocarbon such as an alkane.Thus, for example, when a highly unsaturated hydrocarbon is converted toa less unsaturated hydrocarbon without further hydrogenating such a lessunsaturated hydrocarbon to a saturated hydrocarbon, the hydrogenationprocess is “more selective” than when such highly unsaturatedhydrocarbon is hydrogenated to a less unsaturated hydrocarbon and thenfurther hydrogenated to a saturated hydrocarbon.

The term “n-butenes” refers to 1-butenes, cis-2-butenes, andtrans-2-butenes.

According to the present invention, a catalyst composition which can beuseful as a catalyst in the selective hydrogenation of a highlyunsaturated hydrocarbon such as a diolefin to a less unsaturatedhydrocarbon such as a monoolefin is provided. The composition cancomprise a carburized, calcined, modified zeolite wherein the modifiedzeolite comprises a zeolite, a Group VIB metal selected from the groupconsisting of chromium, molybdenum, tungsten, and combinations thereof,and an inorganic support. Examples of suitable inorganic supportsinclude, but are not limited to, silica, alumina, titanium dioxide,zirconia, a spinel such as zinc aluminate, zinc titanate, magnesiumaluminate, calcium aluminate, and the like and combinations thereof. Thepresently preferred inorganic support is an alumina selected from thegroup consisting of alpha alumina, beta alumina, delta alumina, etaalumina, gamma alumina, and the like and combinations thereof. The morepreferred inorganic support is gamma alumina. The composition can alsocomprise a carburized, calcined, modified zeolite wherein the modifiedzeolite is a mixture or an extruded mixture comprising a zeolite, aGroup VIB metal, and an inorganic support.

Any commercially available zeolite can be employed in the presentinvention as long as such zeolite is effective in selectivelyhydrogenating a highly unsaturated hydrocarbon to a less unsaturatedhydrocarbon when used according to the present invention. The presentlypreferred zeolites are beta zeolite, zeolite X, zeolite Y, zeolite L,and the like and combinations thereof. The more preferred zeolite iszeolite L.

Generally, the catalyst composition can comprise a metal of Group VIB ofthe Periodic Table of the Elements (i.e., a Group VIB metal) in anyweight percent so long as such weight percent is effective inselectively hydrogenating a highly unsaturated hydrocarbon such as adiolefin to a less unsaturated hydrocarbon such as a monoolefin. Thecatalyst composition comprises a Group VIB metal in the range of fromabout 1 weight percent Group VIB metal based on the total weight of thecatalyst composition to about 95 weight percent Group VIB metal,preferably in the range of from about 5 weight percent Group VIB metalto about 80 weight percent Group VIB metal and, more preferably, in therange of from about 10 weight percent Group VIB metal to about 60 weightpercent Group VIB metal.

Generally, the catalyst composition can comprise a zeolite in any weightpercent so long as such weight percent is effective in selectivelyhydrogenating a highly unsaturated hydrocarbon such as a diolefin to aless unsaturated hydrocarbon such as a monoolefin. The catalystcomposition comprises a zeolite in the range of from about 1 weightpercent zeolite based on the total weight of the catalyst composition toabout 95 weight percent zeolite, preferably in the range of from about 5weight percent zeolite to about 80 weight percent zeolite and, morepreferably, in the range of from about 10 weight percent zeolite toabout 60 weight percent zeolite.

Generally, the catalyst composition can comprise an inorganic support inany weight percent so long as such weight percent is effective inselectively hydrogenating a highly unsaturated hydrocarbon such as adiolefin to a less unsaturated hydrocarbon such as a monoolefin. Thecatalyst composition comprises an inorganic support in the range of fromabout 1 weight percent inorganic support based on the total weight ofthe catalyst composition to about 90 weight percent inorganic support,preferably in the range of from about 5 weight percent inorganic supportto about 80 weight percent inorganic support and, more preferably, inthe range of from about 10 weight percent inorganic support to about 60weight percent inorganic support.

Generally, the catalyst composition can comprise carbon in any weightpercent so long as such weight percent is effective in selectivelyhydrogenating a highly unsaturated hydrocarbon such as a diolefin to aless unsaturated hydrocarbon such as a monoolefin. The catalystcomposition comprises carbon in the range of from about 0.1 weightpercent carbon based on the total weight of the catalyst composition toabout 90 weight percent carbon, preferably in the range of from about0.5 weight percent carbon to about 60 weight percent carbon and, morepreferably, in the range of from about 1 weight percent carbon to about50 weight percent carbon.

Any metal of Group VIB of the Periodic Table of the Elements (i.e., aGroup VIB metal) such as chromium, molybdenum, tungsten, and the likeand combinations thereof can be employed in the present invention. Thepresently preferred Group VIB metal is molybdenum. Preferably, whenpreparing a catalyst composition disclosed herein, such Group VIB metalis present in a Group VIB metal-containing compound. Preferably, suchGroup VIB metal or Group VIB metal-containing compound is selected suchthat it can be combined with, or incorporated therein or thereon, azeolite, or a zeolite and an inorganic support, of the presentinvention. And, preferably, such Group VIB metal or Group VIBmetal-containing compound is selected so that, as compared to use of azeolite only, or zeolite and inorganic support only, it is moreeffective in a catalyst composition of the present invention inselectively hydrogenating a highly unsaturated hydrocarbon such as adiolefin to a less unsaturated hydrocarbon such as a monoolefin.

Generally, any molybdenum compound which, when combined with a zeolite,or a zeolite and an inorganic support, according to the presentinvention, is effective in selectively hydrogenating a highlyunsaturated hydrocarbon such as a diolefin to a less unsaturatedhydrocarbon such as a monoolefin can be used in the present invention.Examples of suitable molybdenum compounds include, but are not limitedto, molybdenum chloride, molybdenum acetate, molybdenum fluoride,molybdenum hexacarbonyl, molybdenum sulfide, sodium molybdates,potassium molybdates, molybdenum oxychloride, molybdenum sulfide,ammonium tetrathiomolybdate, ammonium molybdate, ammonium dimolybdate,ammonium heptamolybdate, molybdenum oxides, and the like andcombinations thereof. The molybdenum can have any suitable oxidationstate such as 2, 3, 4, 5, and 6. The presently preferred molydenumcompound is molybdenum oxide.

Generally, any tungsten compound which, when combined with a zeolite, ora zeolite and an inorganic support, according to the present invention,is effective in selectively hydrogenating a highly unsaturatedhydrocarbon such as a diolefin to a less unsaturated hydrocarbon such asa monoolefin can be used in the present invention. Examples of suitabletungsten compounds include, but are not limited to, tungstenhexachloride, tungsten tetrachloride, tungsten pentachloride, tungstenhexabromide, tungsten tetrabromide, tungsten pentabromide, tungstenhexafluoride, tungsten tetrafluoride, tungsten pentafluoride, tungstenhexacarbonyl, tungsten oxychloride, tungsten hexasulfide, tungstentetrasulfide, tungsten oxide, tungsten pentasulfide, ammoniummetatungstate, sodium metatungstate, potassium metatungstate, tungsticacid and the like and combinations thereof. The presently preferredtungsten compound is tungsten oxide.

Generally, any chromium compound which, when combined with a zeolite, ora zeolite and an inorganic support, according to the present invention,is effective in selectively hydrogenating a highly unsaturatedhydrocarbon such as a diolefin to a less unsaturated hydrocarbon such asa monoolefin can be used in the present invention. Examples of suitablechromium compounds include, but are not limited to, chromium acetate,chromium acetylacetonate, chromium chloride, chromium fluoride, chromiumnitrate, hydrated chromium nitrate, chromium nitrate nonahydrate,chromium nitride, chromium oxide, chromium perchlorate, chromiumpotassium sulfate, chromium sulfate, chromium telluride, and the likeand combinations thereof. The presently preferred chromium compound ischromium oxide.

The catalyst composition can be in any physical form and dimension solong as such physical form and dimension is effective in selectivelyhydrogenating a highly unsaturated hydrocarbon such as a diolefin to aless unsaturated hydrocarbon such as a monoolefin. Generally, thecatalyst composition can be characterized by characteristics such asshape, particle size, and surface area. The catalyst composition canhave any suitable shape such as spherical, cylindrical, trilobal, andthe like and combinations thereof. The catalyst composition can have aparticle size generally in the range of from about 1 millimeter (mm) toabout 10 mm, preferably in the range of from about 2 mm to about 8 mm.Generally, the catalyst composition can have a surface area, as measuredby the BET method (Brunauer, Emmett and Teller method) employing N₂ inthe range of from about 0.6 m²/g to about 200 m²/g, preferably in therange of from about 1 m²/g to about 100 m²/g.

According to the present invention, any suitable inorganic support canbe used so long as the catalyst composition can selectively hydrogenatea highly unsaturated hydrocarbon such as a diolefin to a lessunsaturated hydrocarbon such as a monoolefin. Examples of suitableinorganic supports include, but are not limited to, silica, alumina,titanium dioxide, zirconia, a spinel such as zinc aluminate, zinctitanate, magnesium aluminate, calcium aluminate, and the like andcombinations thereof. The presently preferred inorganic support is analumina selected from the group consisting of alpha alumina, betaalumina, delta alumina, eta alumina, gamma alumina, and the like andcombinations thereof. The more preferred inorganic support is gammaalumina.

According to the present invention, a process for producing a catalystcomposition which can be useful as a catalyst composition in thehydrogenation of a highly unsaturated hydrocarbon such as a diolefin toa less unsaturated hydrocarbon such as a monoolefin is provided. Thecatalyst composition can be prepared by any suitable, effective methodor manner which results in a catalyst composition comprising a zeolite,a Group VIB metal, and an inorganic support wherein such catalystcomposition has been calcined and carburized, and can also be preparedby any method or manner which results in the catalyst composition beingeffective in the selective hydrogenation of a highly unsaturatedhydrocarbon to a less unsaturated hydrocarbon.

The process of preparing the catalyst composition can comprise (1)combining a zeolite, a Group VIB metal, and an inorganic support to forma modified zeolite; (2) calcining such modified zeolite under acalcining condition to produce a calcined, modified zeolite; and (3)contacting such calcined, modified zeolite with a carburizing agentunder a carburizing condition to provide a catalyst composition.Generally, the combining of a zeolite, a Group VIB metal, and aninorganic support can be conducted in any suitable manner and in anysuitable order which results in a modified zeolite which can then becalcined and carburized to produce a catalyst composition of the presentinvention. Generally, the amounts of a zeolite, a Group VIB metal, andan inorganic support used are such that when such zeolite, Group VIBmetal, and inorganic support are combined, calcined, and carburizedaccording to the present invention, a catalyst composition is producedhaving weight percents of zeolite, Group VIB metal, and inorganicsupport as disclosed hereinabove.

Any method or manner known to one skilled in the art for carrying outthe combining of the combining step (1) to form a modified zeolite canbe employed in this invention. Generally, the combining step can be anyeffective method to provide a modified zeolite so long as such modifiedzeolite can be calcined and carburized to produce a catalyst compositionwhich is effective in selectively hydrogenating a highly unsaturatedhydrocarbon such as a diolefin to a less unsaturated hydrocarbon such asa monoolefin. The term “modified zeolite” refers to a compositioncontaining a zeolite, a Group VIB metal, and an inorganic support whichcan then be calcined and carburized according to the present inventionto thereby provide the catalyst composition of the present invention.For example, the term “modified zeolite” can refer to a mixture of azeolite, a Group VIB metal, and an inorganic support, an extrudedmixture of a zeolite, a Group VIB metal, and an inorganic support, or adried extruded mixture of a zeolite, a Group VIB metal, and an inorganicsupport.

For example, combining a zeolite, a Group VIB metal, and an inorganicsupport can comprise physically mixing or blending a Group VIB metal orGroup VIB metal-containing compound with a zeolite and an inorganicsupport by stirring, extrusion, blending, kneading, and the like andcombinations thereof. Also for example, a Group VIB metal or Group VIBmetal-containing compound can be combined with a zeolite and aninorganic support by extrusion. The presently preferred technique forcombining a zeolite, a Group VIB metal, and an inorganic support tothereby provide a modified zeolite which can be calcined and carburizedto thereby provide a catalyst composition of the present invention is byphysical mixing such zeolite in powder form, a Group VIB metal or GroupVIB metal-containing compound in powder form, and an inorganic supportin powder form to thereby provide a mixture which is then extruded.

Generally, any suitable means for mixing a zeolite, a Group VIB metal,and an inorganic support can be employed. Examples of suitable mixingmeans for use in preparing a mixture of a zeolite, a Group VIB metal,and an inorganic support of the inventive method are described in detailin Perry's Chemical Engineers' Handbook, Sixth Edition, published byMcGraw-Hill, Inc., copyright 1984, at pages 21-3 through 21-10, whichpages are incorporated herein by reference. Thus, examples of suitablemixing means can include, but are not limited to, devices such astumblers, stationary shells or troughs, muller mixers, which are eitherbatch type or continuous type, impact mixers, and the like. It ispreferred to use a muller mixer in the physical mixing of a zeolite, aGroup VIB metal, and an inorganic support. A liquid such as, but notlimited to, water, may be used in the mixing of a zeolite, a Group VIBmetal, and an inorganic support to thereby provide a mixture.

The mixture of a zeolite, a Group VIB metal, and an inorganic supportcan then be formed or shaped, preferably extruded. Any suitable meansknown to those skilled in the art for forming or shaping, preferablyextruding, the mixture of a zeolite, a Group VIB metal, and an inorganicsupport can be used to achieve the desired formed or shaped mixture,preferably an extruded mixture (i.e., extrudate). A liquid such as, butnot limited to, water, may be used in forming or shaping, preferablyextruding, the mixture of a zeolite, a Group VIB metal, and an inorganicsupport to thereby provide a formed or shaped, preferably extruded,mixture.

Generally, any suitable extruding means for extruding can be used toprovide an extruded mixture of a zeolite, a Group VIB metal, and aninorganic support. Examples of suitable extruding means are described indetail in Perry's Chemical Engineers' Handbook, Sixth Edition, publishedby McGraw Hill, Inc., copyright 1984, at pages 8-60 through 8-72, whichpages are incorporated herein by reference. Thus, examples of suitableextruding means include, but are not limited to, such devices as screwextruders (also known as auger extruders or auger-type extruders) andthe like and combinations thereof. It is presently preferred to use ascrew extruder in the extruding of a mixture of a zeolite, a Group VIBmetal, and an inorganic support.

The mixture, preferably an extruded mixture of a zeolite, a Group VIBmetal, and an inorganic support can be subjected to a drying conditionin an atmosphere of air or inert gas (such as, but not limited to,nitrogen, hydrogen, argon, and the like and combinations thereof) by anymethod(s) or manner known to one skilled in the art. Such dryingcondition includes a temperature in the range of from about 200° C. toabout 1200° C., preferably a temperature in the range of from about 400°C. to about 1000° C. and, most preferably, a temperature in the range offrom about 500° C. to about 900° C. Such drying condition also includesa pressure in the range of from about 7 pounds per square inch absolute(psia) upwardly to about 750 psia, preferably a pressure in the range ofabout 14 psia upwardly to about 450 psia and, most preferably, apressure in the range of from about atmospheric pressure (i.e, about14.7 psia) upwardly to about 25 psia. The drying of the mixture can alsobe carried out under vacuum conditions. Such drying condition alsoincludes a time period in the range of from about 0.5 hour to about 40hours, preferably in the range of from about 1 hour to about 30 hoursand, most preferably, in the range of from about 1.5 hours to about 20hours. The rate of drying the mixture is controlled so as to avoidsurges of water vapor and splattering.

The modified zeolite, preferably a mixture of a zeolite, a Group VIBmetal, and an inorganic support, more preferably an extruded mixture,most preferably a dried extruded mixture, can then be calcined under acalcining condition by any method(s) or manner known to one skilled inthe art to give a calcined, modified zeolite. Generally, such calciningcondition is such as to suitably provide a calcined, modified zeolitewhich can be carburized according to the present invention to produce acatalyst composition which is effective in selectively hydrogenating ahighly unsaturated hydrocarbon such as a diolefin to a less unsaturatedhydrocarbon such as a monoolefin. Preferably, the modified zeolite iscalcined in air.

Generally, such calcining condition includes a temperature in the rangeof from about 100° C. to about 1500° C., preferably in the range of fromabout 200° C. to about 800° C. and, most preferably, in the range offrom about 250° C. to about 700° C. Such calcining condition alsoincludes a pressure in the range of from about 7 pounds per square inchabsolute (psia) to about 750 psia, preferably in the range of from aboutatmospheric pressure (i.e., about 14.7 psia) to about 450 psia and, mostpreferably, in the range of from about atmospheric pressure to about 150psia. Such calcining condition also includes a time period in the rangeof from about 1 hour to about 30 hours, preferably in the range of fromabout 2 hours to about 20 hours and, most preferably, in the range offrom about 3 hours to about 15 hours.

The calcined, modified zeolite can then be contacted with a carburizingagent under a carburizing condition by any method(s) or manner known toone skilled in the art to thereby provide a catalyst composition of thepresent invention.

Generally, any aliphatic hydrocarbon, straight-chained hydrocarbon,branch-chained hydrocarbon, or aromatic hydrocarbon, non-substituted orsubstituted, can be used as the carburizing agent. However, it ispreferred that the hydrocarbon contains in the range of from about 1carbon atom per molecule to about 20 carbon atoms per molecule,preferably in the range of from about 1 carbon atom per molecule toabout 15 carbon atoms per molecule and, most preferably, in the range offrom about 1 carbon atom per molecule to about 10 carbon atoms permolecule. Examples of a suitable hydrocarbon for use as a carburizingagent in the present invention include, but are not limited to, methane,ethane, propane, butanes, isobutane, pentanes, hexanes, heptanes,octanes, nonanes, benzene, toluene, and the like and combinationsthereof. The presently preferred hydrocarbon for use as a carburizingagent in the present invention is methane. The quantity of hydrocarbonrequired for use as a carburizing agent is a quantity that can result ina carburized, calcined, modified zeolite or a catalyst composition ofthe present invention having a weight percent of carbon as disclosedhereinabove. The quantity of carbon which is incorporated with thecatalyst composition of the present invention can be determined by anymeans known to one skilled in the art such as, for example, thermalgravimetric analysis.

Generally, such carburizing condition is such as to suitably provide acatalyst composition which is effective in selectively hydrogenating ahighly unsaturated hydrocarbon such as a diolefin to a less unsaturatedhydrocarbon such as a monoolefin. The carburizing condition forcontacting the calcined, modified zeolite with a carburizing agentincludes a temperature in the range of from about 150° C. to about 1500°C., preferably in the range of from about 200° C. to about 1200° C. and,most preferably, in the range of from about 275° C. to about 1000° C.Such carburizing condition also includes a pressure that can accommodatethe temperature ranges, preferably about atmospheric pressure (i.e.,about 14.7 pounds per square inch), and a time period in the range offrom about 1 hour to about 40 hours, preferably in the range of fromabout 1 hour to about 20 hours and, most preferably, in the range offrom about 1.5 hours to about 15 hours. The carburizing agent isdelivered at a flow rate generally in the range of from about 25milliliters per minute (mL/min) to about 500 mL/min, preferably in therange from about 50 mL/min to about 400 mL/min and, most preferably, inthe range of from about 75 mL/min to about 300 mL/min.

Preferably, the carburizing is carried out in the presence of a gas thatis inert to the contacting of the calcined, modified zeolite andcarburizing agent, such as hydrogen, helium, argon, nitrogen, andcombinations thereof. The presently preferred inert gas is hydrogendelivered at a hydrogen flow rate in the range of from about 200 mL/minto about 1200 mL/min, preferably at a hydrogen flow rate in the range offrom about 250 mL/min to about 1000 mL/min and, most preferably, at ahydrogen flow rate in the range of from about 300 mL/min to about 800mL/min.

According to the present invention, a process for selectivelyhydrogenating a highly unsaturated hydrocarbon such as a diolefin to aless unsaturated hydrocarbon such as a monoolefin is provided. Theprocess can comprise contacting a hydrocarbon-containing fluid whichcomprises one or more highly unsaturated hydrocarbons such as analkyne(s) and/or diolefin(s) with the catalyst composition disclosedherein in the presence of hydrogen in a hydrogenation zone under ahydrogenation condition to selectively hydrogenate such one or morehighly unsaturated hydrocarbons to a less unsaturated hydrocarbon suchas monoolefin.

Hydrogen can be present either in the hydrocarbon-containing fluid or ina hydrogen-containing fluid which is mixed with thehydrocarbon-containing fluid before contacting with the catalystcomposition disclosed herein. If a hydrogen-containing fluid is used, itcan be a substantially pure hydrogen or any fluid containing asufficient concentration of hydrogen to effect the hydrogenationdisclosed herein. It can also contain other gases such as, for example,nitrogen, methane, carbon monoxide, carbon dioxide, steam, orcombinations thereof so long as the hydrogen-containing fluid contains asufficient concentration of hydrogen to effect the hydrogenationdisclosed herein.

Optionally, the catalyst composition can be first treated, prior to thehydrogenation disclosed herein, with a hydrogen-containing fluid toactivate the catalyst composition. Such reductive, or activation,treatment can be carried out at a temperature generally in the range offrom about 20° C. to about 500° C., preferably in the range of fromabout 30° C. to about 450° C. and, most preferably, in the range of from30° C. to 400° C. for a time period in the range of from about 1 minuteto about 30 hours, preferably in the range of from about 0.5 hour toabout 25 hours and, most preferably, in the range of from 1 hour to 20hours at a pressure generally in the range of from about 1 pound persquare inch absolute to about 1000 pounds per square inch absolute(psia), preferably in the range of from about 14.7 psia to about 500psia and, most preferably, in the range of from 14.7 psia to 200 psia.When this optional reductive treatment is not carried out, the hydrogengas present in the reaction medium accomplishes this reduction duringthe initial phase of the hydrogenation process(es) of this invention.

The highly unsaturated hydrocarbon(s) is generally present in thehydrocarbon-containing fluid as an impurity generally at a level foundin typical commercial feed streams. The highly unsaturatedhydrocarbon(s) is generally present in the hydrocarbon-containing fluidin the range of from about 1 part by weight highly unsaturatedhydrocarbon(s) per billion parts by weight hydrocarbon-containing fluid(i.e., about 1 ppb) to about 50,000 parts by weight highly unsaturatedhydrocarbon(s) per million parts by weight hydrocarbon-containing fluid(i.e., about 50,000 ppm), typically at a level in the range of fromabout 10 ppb to about 40,000 ppm and, most typically, at a level in therange of from about 100 ppb to about 30,000 ppm.

The hydrocarbon-containing fluid of the selective hydrogenation processof this invention can also comprise one or more less unsaturatedhydrocarbon(s) such as a monoolefin(s), one or more saturatedhydrocarbon(s) such as an alkane(s), and one or more aromatichydrocarbons such as benzene, toluene, ethylbenzene, styrene, xylenes,and combinations thereof. These additional hydrocarbons can be presentin the hydrocarbon-containing fluid at a level in the range of fromabout 0.001 weight percent to about 99.999 weight percent.

Examples of suitable alkynes include, but are not limited to, acetylene,propyne (also referred to as methylacetylene), 1-butyne, 2-butyne,1-pentyne, 2-pentyne, 3-methyl-1-butyne, 1-hexyne, 1-heptyne, 1-octyne,1-nonyne, 1-decyne, and the like and combinations thereof. The presentlypreferred alkynes are acetylene and propyne.

The alkynes are primarily hydrogenated to the corresponding alkenes. Forexample, acetylene is primarily hydrogenated to ethylene; propyne isprimarily hydrogenated to propylene; and the butynes are primarilyhydrogenated to the corresponding butenes (e.g., n-butenes).

Examples of suitable diolefins include those containing in the range offrom 3 carbon atoms per molecule to about 12 carbon atoms per molecule.Examples of suitable diolefins include, but are not limited to,propadiene, 1,2-butadiene, 1,3-butadiene, isoprene, 1,2-pentadiene,1,3-pentadiene, 1,4-pentadiene, 1,2-hexadiene, 1,3-hexadiene,1,4-hexadiene, 1,5-hexadiene, 2-methyl-1,2-pentadiene,2,3-dimethyl-1,3-butadiene, heptadienes, methylhexadienes, octadienes,methylheptadienes, dimethylhexadienes, ethylhexadienes,trimethylpentadienes, methyloctadienes, dimethylheptadienes,ethyloctadienes, trimethylhexadienes, nonadienes, decadienes,undecadienes, dodecadienes, cyclopentadienes, cyclohexadienes,methylcyclopentadienes, cycloheptadienes, methylcyclohexadienes,dimethylcyclopentadienes, ethylcyclopentadienes, dicyclopentadiene (alsoknown as tricyclo[5.2.1]^(2,6)deca-3,8-diene), and the like andcombinations thereof.

Presently preferred diolefins are propadiene, 1,2-butadiene,1,3-butadiene, isoprene, 1,2-pentadiene, 1,3-pentadiene, 1,4-pentadiene,cyclopentadienes (such as 1,3-cyclopentadiene), dicyclopentadiene (alsoknown as tricyclo[5.2.1]^(2,6)deca-3,8-diene), and combinations thereof.These diolefins are preferably selectively hydrogenated to theircorresponding monoolefins containing the same number of carbon atoms permolecule as the diolefins. For example, propadiene is selectivelyhydrogenated to propylene; 1,2-butadiene and 1,3-butadiene areselectively hydrogenated to n-butenes; 1,3-pentadiene and 1,4-pentadieneare selectively hydrogenated to 1-pentene and 2-pentene; isoprene isselectively hydrogenated to methyl-1-pentene and methyl-2-pentene; and1,3-cyclopentadiene is selectively hydrogenated to cyclopentene. Themore presently preferred diolefin is 1,3-butadiene.

Examples of suitable monoolefins include, but are not limited to,ethylene, propylene, n-butenes (also referred to as normal butenes whichinclude 1-butenes, cis-2-butenes, and trans-2-butenes), isobutylene,1-pentene, 2-pentene, methyl-1-butene (such as 2-methyl-1-butene),methyl-2-butene (such as 2-methyl-2-butene), 1-hexene, 2-hexene,3-hexene, methyl-1-pentene, 2,3-dimethyl-1-butene, 1-heptene, 2-heptene,3-heptene, methyl-1-hexene, methyl-2-hexene, methyl-3-hexene,dimethylpentenes, ethylpentenes, octenes, methylheptenes,dimethylhexenes, ethylhexenes, nonenes, methyloctenes, dimethylheptenes,ethylheptenes, trimethylhexenes, cyclopentenes, cyclohexenes,methylcyclopentenes, cycloheptenes, methylcyclohexenes,dimethylcyclopentenes, ethylcyclopentenes, cyclooctenes,methylcycloheptenes, dimethylcyclohexenes, ethylcyclohexenes,trimethylcyclohexenes, methylcyclooctenes, dimethylcyclooctenes,ethylcyclooctenes, and the like and combinations thereof.

Examples of suitable saturated hydrocarbons include, but are not limitedto, methane, ethane, propane, butanes, methylpropanes, methylbutanes,dimethylbutanes, pentanes, hexanes, and the like and combinationsthereof.

Examples of suitable aromatic hydrocarbons include, but are not limitedto, benzene, toluene, ethylene, styrene, xylenes, and the like andcombinations thereof.

Furthermore, the hydrocarbon-containing fluid can contain in the rangeof from about 0.001 weight percent hydrogen to about 20 weight percenthydrogen, and up to 10,000 parts per million by volume (ppmv) of carbonmonoxide.

It is within the scope of this invention to have additional compounds(such as water, alcohols, ethers, aldehydes, ketones, carboxylic acids,esters and other oxygenated compounds) present in thehydrocarbon-containing fluid, as long as such additional compounds donot significantly interfere with the selective hydrogenation process ofa highly unsaturated hydrocarbon to a less unsaturated hydrocarbon asdescribed herein.

In a preferred embodiment of the present invention, thehydrocarbon-containing fluid contains 1,3-butadiene and essentially noother hydrocarbons. In other words, the hydrocarbon-containing fluid isa 1,3-butadiene stream. Preferably, the 1,3-butadiene is selectivelyhydrogenated to n-butenes (i.e., normal butenes which include 1-butenes,cis-2-butenes, and trans-2-butenes) without further hydrogenating suchn-butenes to butane.

The selective hydrogenation process(es) of this invention is generallycarried out by contacting a hydrocarbon-containing fluid comprising atleast one highly unsaturated hydrocarbon, in the presence of hydrogen,with a catalyst composition of this invention under a hydrogenationcondition. The hydrocarbon-containing fluid can be contacted by anysuitable manner with a catalyst composition described herein which iscontained within a hydrogenation zone. Such hydrogenation zone cancomprise, for example, a reactor vessel.

The contacting step, of contacting the hydrocarbon-containing fluid witha catalyst composition disclosed herein, can be operated as a batchprocess step or, preferably, as a continuous process step. In the latteroperation, a solid or fixed catalyst bed or a moving catalyst bed or afluidized catalyst bed can be employed. Preferably, a fixed catalyst bedis employed. Any of these operational modes have advantages anddisadvantages, and those skilled in the art can select the one mostsuitable for a particular hydrocarbon-containing fluid and catalystcomposition.

The contacting step is preferably carried out within a hydrogenationzone, wherein is contained a catalyst composition disclosed herein, andunder a hydrogenation condition that suitably promotes the selectivehydrogenation of a highly unsaturated hydrocarbon to a less unsaturatedhydrocarbon as described herein. Such hydrogenation condition should besuch as to avoid significant hydrogenation of a less unsaturatedhydrocarbon(s) being initially present in the hydrocarbon-containingfluid to a saturated hydrocarbon(s) such as an alkane(s) orcycloalkane(s).

Generally, such hydrogenation process comprises the presence ofhydrogen, preferably hydrogen gas, in an amount in the range of fromabout 0.1 mole of hydrogen employed for each mole of highly unsaturatedhydrocarbon present in the hydrocarbon-containing fluid to about 1000moles of hydrogen employed for each mole of highly unsaturatedhydrocarbon present in the hydrocarbon-containing fluid, preferably inthe range of from about 0.5 mole to about 500 moles of hydrogen employedfor each mole of highly unsaturated hydrocarbon present in thehydrocarbon-containing fluid and, most preferably, in the range of fromabout 0.7 mole to about 200 moles of hydrogen employed for each mole ofhighly unsaturated hydrocarbon present in the hydrocarbon-containingfluid.

Generally, such hydrogenation condition comprises a temperature and apressure necessary for the selective hydrogenation process of thisinvention depending largely upon the activity of the catalystcomposition, the hydrocarbon-containing fluid composition, and thedesired extent of hydrogenation. Generally, such temperature is in therange of from about 10° C. to about 600° C., preferably in the range offrom about 20° C. to about 500° C. and, most preferably, in the range offrom 30° C. to 450° C. A suitable pressure is generally in the range offrom about 0 pounds per square inch gauge (psig) to about 2000 psig,preferably in the range of from about 0 psig to about 1500 psig and,most preferably, in the range of from about 0 psig to about 1000 psig.

Such hydrogenation condition further comprises the flow rate at whichthe hydrocarbon-containing fluid is charged (i.e., the charge rate ofhydrocarbon-containing fluid) to the hydrogenation zone. The flow rateis such as to provide a gas hourly space velocity (“GHSV”) generallyexceeding 1 liter/liter/hour. The term “gas hourly space velocity”, asused herein, shall mean the numerical ratio of the rate at which ahydrocarbon-containing fluid is charged to the hydrogenation zone inliters per hour at standard condition of temperature and pressure(“STP”) divided by the liters of catalyst composition contained in thehydrogenation zone to which the hydrocarbon-containing fluid is charged.Typically, the gas hourly space velocity of the hydrocarbon-containingfluid will be in the range of from about 1 to about 30,000 liters ofhydrocarbon-containing fluid per liter of catalyst per hour(liter/liter/hour), preferably in the range of from about 2 to about20,000 liter/liter/hour and, most preferably, in the range of from about3 to about 10,000 liter/liter/hour.

If it is desired to regenerate the catalyst composition of thisinvention after prolonged use in the selective hydrogenation process(es)described herein, the regeneration can be accomplished by calcining thecatalyst composition in an oxidizing atmosphere such as in air at atemperature that does not exceed about 700° C. to bum off carbonaceousand sulfur deposits.

The following examples are presented to further illustrate thisinvention and are not to be construed as unduly limiting the scope ofthis invention.

EXAMPLE I

This example illustrates the preparation of variousmolybdenum-containing catalysts to be used in a selective hydrogenationprocess.

Catalyst A (Control)

A 15.0 gram quantity of molybdenum oxide (MoO₃) in powder form wascombined with 25.0 grams of a commercially available alumina (Al₂O₃)support in powder form (such alumina support had been provided by UnitedCatalyst Inc. (UCI), Louisville, Ky. under the product designation of“CATAPAL D”) by physically mixing the MoO₃ and the CATAPAL D. Themixture was then extruded to provide an extrudate having a diameter of{fraction (1/16)} inch (i.e., a {fraction (1/16)} inch extrudate). Themolybdenum-and-alumina extrudate was then calcined in air at 538° C. for6 hours to produce 30.8 grams of Control Catalyst A. Control Catalyst Acontained 30.8 weight percent molybdenum (Mo).

Catalyst B (Control)

A 22.4 gram quantity of the above-described Control Catalyst A washeated, in a gas mixture of methane (CH₄) and hydrogen (H₂) at ahydrocarbon (methane, CH₄) flow rate of 150 mL/min and a hydrogen (H₂)flow rate of 600 mL/min, from a temperature of 400° C. to 705° C. over atime period of 5 hours followed by heating at 700° C. for 2 hours toprovide 21.0 grams of Control Catalyst B. Control Catalyst B contained66 weight percent molybdenum carbide (Mo₂C). X-ray data confirmed thatthe molybdenum carbide had a hexagonal structure and a crystallinedomain size of 8 angstoms. The “crystalline domain size” was determinedfrom the line broadening of the X-ray diffraction profile.

Catalyst C (Invention)

A 5.0 gram quantity of molybdenum oxide (MoO₃) in powder form wascombined with 12.0 grams of a commercially available alumina (Al₂O₃)support in powder form (such alumina support had been provided by UnitedCatalyst Inc. (UCI), Louisville, Kentucky under the product designationof “CATAPAL D”) and 1.0 gram of commercially available zeolite L inpowder form (such zeolite L had been provided by CU Chemie Uetikon AG,Switzerland, under the product designation “K-LTL ZEOCAT”) by physicallymixing the MoO₃, CATAPAL D, and zeolite L. The mixture was then extrudedto provide an extrudate having a diameter of {fraction (1/16)} inch(i.e., a {fraction (1/16)} inch extrudate). Themolybdenum-alumina-zeolite extrudate was then calcined in air at 538° C.for 6 hours to produce 21.5 grams of a modified zeolite. A 20.3 gramquantity of such modified zeolite was then heated, in a gas mixture ofmethane (CH₄) and hydrogen (H₂) at a hydrocarbon (methane, CH₄) flowrate of 150 mL/min and a hydrogen (H₂) flow rate of 600 mL/min, from atemperature of 400° C. to 705° C. over a time period of 5 hours followedby heating at 700° C. for 2 hours to provide 19.0 grams of InventionCatalyst C. Invention Catalyst C contained 70 weight percent molybdenumcarbide (Mo₂C). X-ray data confirmed that the molybdenum carbide had ahexagonal structure and a crystalline domain size of 7 angstoms. The“crystalline domain size” was determined from the line broadening of theX-ray diffraction profile.

EXAMPLE II

This example illustrates the performance of the catalysts describedhereinabove in Example I in a selective hydrogenation process.

A 3.4 gram quantity of Control Catalyst A (the runs were repeated usinga 3.3 gram quantity of Control Catalyst B and a 2.7 gram quantity ofInvention Catalyst C) was placed in a stainless steel reactor tubehaving a 0.62 inch inner diameter and a length of about 18 inches. Thecatalyst (resided in the middle of the reactor, both ends of the reactorwere packed with 6 mL of 3 mm glass beads) was reduced at about 380° C.for about 1 hour under hydrogen gas flowing at 12 liters per hour at 0pounds per square inch gauge (psig). Thereafter, while maintaining ahydrogen gas flow rate of 6 liters per hour (L/hr) at 0 psig, ahydrocarbon-containing fluid containing 1,3-butadiene having a densityof 2.204 gram per milliliter (g/mL) and a molecular weight of 54.07 wascontinuously introduced into the reactor at a rate of about 6.0 L/hr(resulting in a weight hourly space velocity (“WHSV”) of about 4 to 5hour⁻¹). The hydrogen gas flow rate was such as to maintain a hydrogento highly unsaturated hydrocarbon (1,3-butadiene) (H2:HC) mole ratio ofabout 1. The reactor was then heated to a reaction temperature of about370° C. over about an 8-hour time period for Control Catalyst A andInvention Catalyst C. A reaction temperature of 300° C. was used forControl Catalyst B because at 300° C. all 1,3-butadiene present in thehydrocarbon-containing fluid had been converted. The formed reactionproduct exited the reactor tube and passed through several ice-cooledtraps. The liquid portion remained in these traps and was weighed,whereas the volume of the gaseous portion which exited the traps wasmeasured in a “wet test meter”. Liquid and gaseous product samples(collected at hourly intervals) were analyzed by means of a gaschromatograph. Results of test runs for Catalysts A, B, and C aresummarized in Table I. All test data were obtained after about 7 hourson stream.

Various n-butenes selectivities for each of the above-describedcatalysts are shown below in Table I. The term “1,3-butadiene weightpercent conversion” refers to the weight percent of the feed(1,3-butadiene) which was hydrogenated to a hydrocarbon other than1,3-butadiene. The term “n-butenes (or ΣC₄═) selectivity” refers to themole percent of feed (1,3-butadiene) which was hydrogenated to thedesired n-butenes (1-butenes, cis-2-butenes, and trans-2-butenes). Then-butenes selectivity value is representative of the amount of desiredn-butenes (1-butenes, cis-2-butenes, and trans-2-butenes) contained inthe process effluent as opposed to undesired product, i.e., butane.Thus, a higher value for n-butenes selectivity indicated that lessbutane was produced and that the catalyst was more selective or had abetter selectivity to n-butenes.

TABLE I n-butenes Time on 1,3-BD (or ΣC₄=) Catalyst Stream Temp wt %mole % Catalyst Preparation (hr) (° C.) conversion^(d) selectivity^(e)Catalyst A MoO₃ + 7.14 371 48.9 78.4 (Control)^(a) alumina (Calcined)Catalyst B MoO₃ + 7.00 301 100.0 13.8 (Control)^(b) alumina (Calcinedand Carburized) Catalyst C MoO₃ + 7.15 376 96.2 98.0 (Invention)^(c)alumina + zeolite L (Calcined and Carburized) ^(a)Catalyst A (Control)MoO₃ was combined with alumina and then calcined. ^(b)Catalyst B(Control) MoO₃ was combined with alumina and then calcined andcarburized. ^(c)Catalyst C (Invention) MoO₃ was combined with aluminaand a zeolite L and then calcined and carburized. ^(d)1,3-BD wt %conversion represents the weight percent of the feed (1,3-butadiene)that was hydrogenated. ^(e)n-butenes (or ΣC₄=) mole % selectivityrepresents the mole percent of 1,3-butadiene which was converted to thedesired n-butenes (1-butenes, cis-2-butenes, and trans-2-butenes)contained in the process effluent as opposed to undesired product suchas butane.

Test data in Table I clearly show that Invention Catalyst C producedless undesirable product, i.e., butane, than Control Catalysts A and B.In other words, Invention Catalyst C had better selectivity to n-butenesthan Control Catalysts A or B. For example, at a 1,3-butadieneconversion of 96.2 weight percent, Invention Catalyst C was already at98.0 mole percent selectivity to n-butenes whereas Control Catalyst B,after 100.0 weight percent of the 1,3-butadiene was converted, produceda mere 13.8 mole percent selectivity to n-butenes. In addition, ControlCatalyst A exhibited a better mole percent selectivity to n-butenes(78.4) than Control Catalyst B, but only converted 48.9 weight percentof the 1,3-butadiene. The data demonstrate that Invention Catalyst C isclearly superior in attaining a high weight percent conversion of1,3-butadiene (96.2) while attaining a very high mole percentselectivity to n-butenes (98.0).

The performance of Invention Catalyst C, as compared to ControlCatalysts A and B, is superior in hydrogenating a highly unsaturatedhydrocarbon such as 1,3-butadiene to a less unsaturated hydrocarbon suchas n-butenes (1-butenes, cis-2-butenes, and trans-2-butenes) withoutfurther hydrogenating to a saturated hydrocarbon such as butane. Theimprovement in catalyst performance is believed to be due to the novelprocess of using a catalyst composition prepared by combining a zeolite,a Group VIB metal, and an inorganic support to provide a modifiedzeolite which is then calcined and carburized.

The results shown in the above examples clearly demonstrate that thepresent invention is well adapted to carry out the objects and attainthe ends and advantages mentioned as well as those inherent therein.

Reasonable variations, modifications, and adaptations can be made withinthe scope of the disclosure and the appended claims without departingfrom the scope of this invention.

What is claimed is:
 1. A process for preparing a catalyst compositionuseful in contacting a hydrocarbon-containing fluid which comprises ahighly unsaturated hydrocarbon, in the presence of hydrogen, with saidcatalyst composition in a hydrogenation zone under a hydrogenationcondition effective to hydrogenate said highly unsaturated hydrocarbonto a less unsaturated hydrocarbon wherein said process for preparingsaid catalyst composition comprises: (1) combining a zeolite, a GroupVIB metal, and an inorganic support to form a modified zeolite; (2)calcining said modified zeolite under a calcining condition to produce acalcined, modified zeolite; and (3) contacting said calcined, modifiedzeolite with a carburizing agent under a carburizing condition toprovide said catalyst composition.
 2. A process according to claim 1wherein said combining of said combining step (1) comprising mixing saidzeolite, said Group VIB metal, and said inorganic support to form amixture and then extruding said mixture to form said modified zeolite.3. A process according to claim 2 wherein said mixing comprisessubjecting said zeolite, said Group VIB metal, and said inorganicsupport to a mixing means to provide said mixture.
 4. A processaccording to claim 3 wherein said mixing means is selected from thegroup consisting of tumblers, stationary shells or troughs, mullermixers, impact mixers, and combinations thereof.
 5. A process accordingto claim 4 wherein said mixing means comprises a muller mixer.
 6. Aprocess according to claim 2 wherein said extruding comprises subjectingsaid mixture to an extruding means to provide an extruded mixture.
 7. Aprocess according to claim 6 wherein said extruding means is selectedfrom the group consisting of screw extruders, auger extruders,auger-type extruders, and combinations thereof.
 8. A process accordingto claim 7 wherein said extruding means comprises a screw extruder.
 9. Aprocess according to claim 1 wherein said catalyst composition comprisessaid zeolite in an amount in the range of from about 1 weight percentsaid zeolite based on the total weight of said catalyst composition toabout 95 weight percent, said catalyst composition comprises said GroupVIB metal in an amount in the range of from about 1 weight percent saidGroup VIB metal based on the total weight of said catalyst compositionto about 95 weight percent, and said catalyst composition comprises saidinorganic support in an amount in the range of from about 1 weightpercent said inorganic support based on the total weight of saidcatalyst composition to about 90 weight percent.
 10. A process accordingto claim 1 wherein said calcining condition comprises: a temperature inthe range of from about 100° C. to about 1500° C.; a time period in therange of from about 1 hour to about 30 hours; and a pressure in therange of from about 7 pounds per square inch absolute (psia) to about750 psia.
 11. A process according to claim 1 wherein said carburizingagent comprises a hydrocarbon.
 12. A process according to claim 11wherein said hydrocarbon contains in the range of from about 1 carbonatom per molecule to about 20 carbon atoms per molecule.
 13. A processaccording to claim 12 wherein said hydrocarbon is selected from thegroup consisting of methane, ethane, propane, butanes, isobutane,pentanes, hexanes, heptanes, octanes, nonanes, benzene, toluene, andcombinations thereof.
 14. A process according to claim 13 wherein saidhydrocarbon is methane.
 15. A process according to claim 1 wherein saidcarburizing condition comprises: the presence of hydrogen delivered at ahydrogen flow rate in the range of from about 200 mL/min to about 1200mL/min; a temperature in the range of from about 150° C. to about 1500°C.; a time period in the range of from about 1 hour to about 40 hours;and said carburizing agent is delivered at a flow rate in the range offrom about 25 mL/min to about 500 mL/min.
 16. A process according toclaim 1 wherein said zeolite is selected from the group consisting ofbeta zeolite, zeolite X, zeolite Y, zeolite L, and combinations thereof.17. A process according to claim 16 wherein said zeolite is zeolite L.18. A process according to claim 1 wherein said group VIB metal isselected from the group consisting of chromium, molybdenum, tungsten,and combinations thereof.
 19. A process according to claim 18 whereinsaid group VIB metal is molybdenum.
 20. A process according to claim 19wherein said molybdenum is present in a molybdenum compound selectedfrom the group consisting of molybdenum chloride, molybdenum acetate,molybdenum fluoride, molybdenum hexacarbonyl, molybdenum sulfide, sodiummolybdates, potassium molybdates, molybdenum oxychloride, molybdenumsulfide, ammonium tetrathiomolybdate, ammonium molybdate, ammoniumdimolybdate, ammonium heptamolybdate, molybdenum oxides, andcombinations thereof.
 21. A process according to claim 20 wherein saidmolybdenum compound is molybdenum oxide.
 22. A process according toclaim 1 wherein said inorganic support is selected from the groupconsisting of silica, alumina, titanium dioxide, spinel, andcombinations thereof.
 23. A process according to claim 22 wherein saidinorganic support is an alumina selected from the group consisting ofalpha alumina, beta alumina, delta alumina, eta alumina, gamma alumina,and combinations thereof.
 24. A composition prepared according toclaim
 1. 25. A composition prepared according to claim
 2. 26. Acomposition prepared according to claim
 3. 27. A composition preparedaccording to claim
 4. 28. A composition prepared according to claim 5.29. A composition prepared according to claim
 6. 30. A compositionprepared according to claim
 7. 31. A composition prepared according toclaim
 8. 32. A composition prepared according to claim
 9. 33. Acomposition prepared according to claim
 10. 34. A composition preparedaccording to claim
 11. 35. A composition prepared according to claim 12.36. A composition prepared according to claim
 13. 37. A compositionprepared according to claim
 14. 38. A composition prepared according toclaim
 15. 39. A composition prepared according to claim
 16. 40. Acomposition prepared according to claim
 17. 41. A composition preparedaccording to claim
 18. 42. A composition prepared according to claim 19.43. A composition prepared according to claim
 20. 44. A compositionprepared according to claim
 21. 45. A composition prepared according toclaim
 22. 46. A composition prepared according to claim
 23. 47. Acatalyst composition comprising a modified zeolite comprising a zeolite,a Group VIB metal, and an inorganic support wherein said modifiedzeolite has been calcined under a calcining condition and contacted witha carburizing agent under a carburizing condition to thereby provide acarburized, calcined, modified zeolite.
 48. A catalyst compositionaccording to claim 47 wherein said modified zeolite is a mixturecomprising said zeolite, said Group VIB metal, and said inorganicsupport.
 49. A catalyst composition according to claim 48 wherein saidmodified zeolite is an extruded mixture comprising said zeolite, saidGroup VIB metal, and said inorganic support.
 50. A catalyst compositionaccording to claim 47 wherein said catalyst composition comprises saidzeolite in an amount in the range of from about 1 weight percent saidzeolite based on the total weight of said catalyst composition to about95 weight percent, said catalyst composition comprises said Group VIBmetal in an amount in the range of from about 1 weight percent saidGroup VIB metal based on the total weight of said catalyst compositionto about 95 weight percent, and said catalyst composition comprises saidinorganic support in an amount in the range of from about 1 weightpercent said inorganic support based on the total weight of saidcatalyst composition to about 90 weight percent.
 51. A process accordingto claim 47 wherein said zeolite is selected from the group consistingof beta zeolite, zeolite X, zeolite Y, zeolite L, and combinationsthereof.
 52. A process according to claim 46 wherein said zeolite iszeolite L.
 53. A process according to claim 47 wherein said group VIBmetal is selected from the group consisting of chromium, molybdenum,tungsten, and combinations thereof.
 54. A process according to claim 53wherein said group VIB metal is molybdenum.
 55. A process according toclaim 47 wherein said inorganic support is an alumina selected from thegroup consisting of alpha alumina, beta alumina, delta alumina, etaalumina, gamma alumina, and combinations thereof.